Connection of a support to a molded plastic structure

ABSTRACT

A blow-molded plastic structure, such as a table top, may include an undercut. For example, the table top may include a frame receiving portion and a frame connecting structure with an undercut may be disposed in the frame receiving portion. A first portion of the frame may contact or engage the frame connecting structure when the frame is connected to the table top. In an exemplary embodiment, a first side of the frame receiving portion may include a first frame connecting portion with an undercut and a second side of the frame receiving portion may include a second frame connecting portion with an undercut. The first frame connecting portion with an undercut may be disposed on an opposing surface from the second frame connecting portion with an undercut.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit to U.S. Provisional Patent ApplicationNo. 62/800,318, filed Feb. 1, 2019, titled CONNECTION OF A SUPPORT TO AMOLDED PLASTIC STRUCTURE, which is incorporated herein by reference inits entirety.

BACKGROUND Field of the Invention

The present invention generally relates to structures that are at leastpartially constructed from blow-molded plastic and, more particularly,to blow-molded plastic structures including an undercut.

Description of Related Art

Blow-molding is a manufacturing process by which hollow plastic partsare formed. The blow-molding process typically begins with a hollow tubeof molten plastic, which is commonly referred to as a parison. Theparison is clamped into a mold and air is blown into the parison. Theair pressure pushes the plastic into the faces of the mold so that theplastic takes the shapes of the mold. Once the plastic has cooled, themold may be opened and the part may be ejected from the mold.

In greater detail, conventional blow-molding machines include a moldwith two halves and the blow-molding process is initiated with the twomold halves spaced apart. The parison or tube of plastic is extrudedbetween the mold halves and then the mold halves are moved horizontallytoward one another. The parison, which is disposed within the mold, isinflated with pressured air, which is typically between about 60 psi andabout 150 psi. The parison expands into contact with the inner surfaceof the molds and the plastic is formed into the desired shape.Thereafter, the air pressure is reduced and the mold halves areseparated to allow the blow-molded plastic article to be removed.

The blow-molding process is typically used to create hollow plasticstructures such as bottles and containers. The blow-molding process mayallow hollow plastic objects to be manufactured economically and in highvolume. In addition, the blow-molding process may allow thin-walledobjects to be quickly manufactured. Because blow-molded structuresinclude a hollow interior portion and each mold half forms its own wallshape, a variety of different types of structures can be constructedusing the blow-molding process.

The type and configuration of blow-molded plastic objects that may beformed, however, may be limited by the hollow interior portion. The typeand configuration of blow-molded plastic objects that may be formed mayalso be limited because pressurized air is required to stretch and pushthe plastic into the faces of the mold during the molding process. Inaddition, the outer wall thickness of a blow-molded plastic structuremay be difficult to control because, as the object being manufactured islarger in size, the more the plastic may have to be stretched andstressed during the molding process.

BRIEF SUMMARY

A need therefore exists for a blow-molded plastic structure, a processfor making blow-molded plastic structure, and/or a method of making ablow-molded plastic structure that eliminates or diminishes theabove-described disadvantages and problems.

One aspect is a structure that may be constructed from plastic. Forexample, the structure may be constructed from molded plastic. Ifdesired, the structure may be constructed from blow-molded plastic.

Another aspect is the structure that may be constructed from blow-moldedplastic. The blow-molded plastic structure may be an article offurniture, such as a table or chair, water sports equipment, such as akayak or paddleboard, a container, such as a bottle or cooler, anenclosure, such as a shed or deck box, and the like. The structure couldalso be component or part of a structure, such as a table top, chairseat, chair back, a component of a kayak, a component of a paddleboard,a component of a cooler, a component of a shed, a component ofplayground equipment, and the like. Additionally, the structure could beother suitable objects, articles, constructions, and the like, such aspanels, sections, segments, and the like.

Still another aspect is a method or process of manufacturing or making ablow-molded plastic structure. The method may include forming ablow-molded plastic structure with one or more features or attributes.The process of manufacturing or making may include forming a blow-moldedplastic structure with one or more features or attributes.

Yet another aspect is a blow-molded plastic structure with an undercutthat is formed during the blow-molding process. The undercut may includean overhang without material on the underside of the overhang. Theundercut may be formed during the molding process without any cuttingaway or removal of material. Thus, for example, an undercut may beformed during the molding process without requiring material to becutaway or removed.

Still yet another aspect is a blow-molded plastic structure with anundercut that is formed during the molding process. The undercut may beformed during the blow-molding process by one or more tools and theundercut may include an overhanging structure and a relief or receivingportion disposed under the overhang. Thus, in an exemplary embodiment,the undercut may include a projection or outcropping and an open spaceunder the projection. Because the open space may be formed during themolding process, no cutting or removal of material may be required.

A further aspect is a blow-molded plastic structure with an undercutthat is formed during the molding process with a movable tool. The toolmay allow the undercut to be formed with sharp edges and/or acuteangles. For example, the blow-molded plastic structure may include anundercut with a surface disposed at an angle of about sixty degrees(60°) or more, about sixty-five degrees (65°) or more, about seventydegrees (70°) or more, about seventy-five degrees (75°) or more, abouteighty degrees (80°) or more, about eighty-five degrees (85°) or more,or about ninety degrees (90°) or more relative to the blow-moldedplastic structure. For instance, a portion of the undercut may bedisposed at a sharp or acute angle relative to a surface of theblow-molded plastic structure and the acute angle may be an angle ofabout sixty degrees (60°) or more, about sixty-five degrees (65°) ormore, about seventy degrees (70°) or more, about seventy-five degrees(75°) or more, about eighty degrees (80°) or more, about eighty-fivedegrees (85°) or more, or about ninety degrees (90°) or more. Theundercut may be formed in such a way that the undercut is notsubstantially deformed or distorted when the structure is removed fromthe mold during the blow-molding process. Thus, in an exemplaryembodiment, an undercut may be formed during the blow-molding process,the undercut may be formed with an acute angle, the undercut may beformed without the removal of any material, and the undercut may not besubstantially deformed or distorted when the structure is removed fromthe mold during the blow-molding process.

Another further aspect is an undercut that may be formed during ablow-molding process and the undercut may be formed by a movable toolduring the molding process. For example, a structure may be formedduring the blow-molding process and the structure may include one ormore undercuts formed during the blow-molding process. The undercuts maybe formed by a tool, which may be movable during the molding process,and the undercuts may include one or more acute angles. In addition, theundercuts may be formed without the removal of material and theundercuts may not be significantly deformed when the structure isremoved from the mold. Advantageously, the acute angles may providesharp corners, abrupt transitions, clearly defined overhangs, clearlydefined reliefs or recesses disposed under the overhangs, etc. Theundercuts may facilitate attachment of items or objects to theblow-molded plastic structure.

A still further aspect is a blow-molded plastic structure may include anundercut formed during the blow-molding process. The undercut may bedisposed in a surface of the blow-molded plastic structure and thesurface of the blow-molded plastic structure may include a generallyplanar, flat, or level portion. The undercut may include a protrusionextending from the generally planar portion with a relief or recessdisposed underneath the protrusion. For example, an undercut may bedisposed in the wall or surface of the blow-molded plastic structure.The undercut may include a protrusion extending outwardly relative tothe generally planar surface of the blow-molded plastic structure and arecess may be disposed underneath the protrusion. The lower surface ofthe protrusion may be disposed at a sharp or acute angle relative to thegenerally planar portion of the blow-molded plastic structure. The lowersurface of the protrusion may also be disposed at a sharp or acute anglerelative to a distal end of the protrusion.

Yet another further aspect is a blow-molded plastic structure that mayinclude a generally planar wall or surface with an undercut. Theblow-molded plastic structure may also include one or more generallyplanar walls or surfaces and one or more undercuts may be formed in thewalls or surfaces. For instance, a first undercut may be disposed on afirst wall or surface and a second undercut may be disposed on a secondwall or surface. The walls or surfaces may have generally parallel,symmetrical, or similar configurations. The undercuts may be generallyaligned or spaced apart depending, for example, upon the intended use ofthe structure.

Advantageously, the undercuts may allow an object to be securelyconnected to the blow-molded plastic structure. For example, theundercut may allow a part or component to be securely connected to theblow-molded plastic structure. The undercut may also facilitateconnection of another object or article to the blow-molded plasticstructure. For instance, the undercut may facilitate connection of aframe to a blow-molded plastic structure. In particular, the undercutmay facilitate connection of a frame to a blow-molded plastic table top.

In greater detail, the undercut may beneficially allow another articleto be securely connected to a blow-molded plastic structure. Forexample, the undercut may engage a portion of frame and the engagementof the frame with the undercut may help create a secure connection. Inaddition, the engagement of the frame with the undercut may help preventunintentional removal of the frame. Further, the undercut may be angledand, depending upon the angle of the undercut, a force applied to theframe may result in more secure connection of the frame to theblow-molded plastic structure. After reviewing this disclosure, oneskilled in the art will appreciate that the undercut may have differentshapes, sizes, configurations, and arrangements depending, for example,upon the intended use of the structure. In addition, after reviewingthis disclosure one skilled in the art will appreciate that the angle ofthe undercut may be sharp or acute, and the undercut may include one ormore angled surfaces.

Another aspect is a blow-molded plastic structure, such as a table top,with an undercut disposed in a lower surface or portion of the tabletop. The undercut may allow a frame to be securely connected to thetable top. For example, the table top may include a frame receivingportion and the frame receiving portion may include one or moreundercuts. In an exemplary embodiment, the frame receiving portion mayinclude one or more surfaces and one or more undercuts may be disposedin one or more of the surfaces. For instance, a first undercut may bedisposed in a first surface of the frame receiving portion and a secondundercut may be disposed in a second surface of the frame receivingportion. The undercuts may be sized and configured to allow the frame tobe inserted into the frame receiving portion and then moved so that theframe and undercuts at least partially engage. The engagement of theframe and undercuts may help secure attach the frame to the table top.In greater detail, the frame may include one or more cutouts and thecutouts may allow the frame to be inserted into the frame receivingportion. The frame may then be moved so that the frame and an engagementsurface of the cutouts engage. The frame may also include one or moreengagement portions that are sized and configured to be disposed inreceiving portions may the frame is attached to the table top. When theengaging portions are disposed in the receiving portions, than may helpprevent unintentional movement of the frame relative to the table top.

Still another aspect is a blow-molded structure, such as a table top,that may include an undercut that is integrally formed during a moldingprocess as part of a unitary, one-piece construction. The unitary,one-piece, blow-molded plastic structure with an undercut may allow aframe to be securely connected to the table top. One skilled in the art,after reviewing this disclosure, will appreciate that the blow-moldedplastic table top and/or frame may have a variety of different shapes,sizes, configurations, and arrangements depending, for example, upon theintended use of the table. Additionally, one skilled in the art, afterreviewing this disclosure, will appreciate that the blow-molded plastictable top with an undercut may have a variety of different features,aspects, characteristics, and the like.

Yet another aspect is a blow-molded plastic structure, such as a tabletop, that may include a receiving portion with an undercut. Thereceiving portion may be sized and configured to receive a structuresuch as a frame and the undercut may facilitate attachment of the frameto the table top. The frame receiving portion may be disposed in thelower surface of a table top and the frame receiving portion with one ormore undercuts may allow a frame to be securely connected to the tabletop. The frame receiving portion with one or more cutouts may eliminatethe need for fasteners to connect the frame to the table top.Advantageously, eliminating or decreasing the need for fasteners toattach the frame to the table top may reduce costs and expedite themanufacturing process.

Still yet another aspect is a blow-molded plastic structure, such as atable top, that may include an undercut that is disposed at an angle.For example, in an exemplary embodiment, the undercut may include asurface that is disposed generally parallel to or at an angle relativeto a lower surface of the table top and/or an upper surface of the tabletop. In another exemplary embodiment, the undercut may include a surfacethat is disposed generally perpendicular to or at an angle relative to asurface of the table top. In still another exemplary embodiment, theundercut may include a surface that is disposed at an angle relative toa generally planar surface of the table top. For example, the undercutmay include a surface that is disposed generally perpendicular to agenerally planar surface of the table top.

A further aspect is a blow-molded plastic structure, such as a tabletop, that may include an undercut with a generally planar surface. Forexample, the lower portion of the undercut may be a generally planarsurface. The generally planar surface of the undercut may be disposedgenerally parallel to or at an angle relative to a lower surface of thetable top and/or an upper surface of the table top. The generally planarsurface of the undercut may also be disposed generally perpendicular toor at an angle relative to a surface of the table top. The generallyplanar surface of the undercut may further be disposed at an angle thatis generally perpendicular to a generally planar surface of the tabletop.

Another further aspect is a blow-molded plastic structure that mayinclude an undercut with a surface that is disposed generallyperpendicular or at an angle relative to a wall of the blow-moldedplastic structure. For example, the surface of the undercut may bedisposed at an acute angle relative to the wall. The undercut may alsoinclude a surface that is disposed at an angle of about ninety degrees(90°) or more relative to the wall, about eighty degrees (80°) or morerelative to the wall, about seventy degrees (70°) or more relative tothe wall, about sixty degrees (60°) or more relative to the wall, orabout fifty degrees (50°) or more relative to the wall. The angle of thesurface of the undercut may be measured, for example, relative to thewall of the blow-molded plastic structure and a lower portion of theundercut.

A still further aspect is blow-molded plastic structure that may includean undercut with an angled surface. The angled surface of the undercutmay facilitate secure engagement of another object to the blow-moldedplastic structure. For instance, the undercut may include angled surfacethat is disposed upwardly at an angle of about two degrees (2°) or more,about four degrees (4°) or more, about six degrees (6°) or more, abouteight degrees (8°) or more, about ten degrees (10°) or more. It will beappreciated that the angle of the surface of the undercut may impact theease at which an object may be attached or disconnected from thestructure. It will also be appreciated that the angle of the surface ofthe undercut may be disposed at other suitable angles depending, forexample, upon the intended use of the structure. It will be furtherappreciated that the undercut may have other suitable shapes, sizes,configurations, and/or arrangements depending, for example, upon theintended use of the structure.

Yet another further aspect is a blow-molded plastic structure that mayinclude an undercut with a surface disposed at a sharp angle. Forexample, the undercut may include an edge, corner, or transition that issharp or abrupt. The transition may be disposed at an angle of aboutninety degrees (90°) or more, about eighty degrees (80°) or more, aboutseventy degrees (70°) or more, about sixty degrees (60°) or more, orabout fifty degrees (50°) or more. The distinct edge or transition ofthe undercut may facilitate attachment of another object to theblow-molded plastic structure. In addition, the undercut have arelatively large receiving portion disposed under the overhang. Theundercut may also provide a relatively large area of contact orengagement, which may further facilitate attachment of another object tothe blow-molded plastic structure. The large receiving portion, thelarge surface area, and/or the sharp angle or transition may facilitatesecure connection of another object to the blow-molded plasticstructure.

Another aspect is a method of forming an undercut in a blow-moldedplastic structure. The method may include forming a protrusion with anundercut in a surface of a blow-molded plastic structure. For example, afirst undercut may be disposed on a first side of a frame receivingportion and a second undercut may be disposed on a second side of theframe receiving portion. The undercut may be formed by a tool with abase and one or more fingers. The fingers may be movable or slidablerelative to the base and the base may include a guide, which may helpcontrol movement of the fingers. The fingers may be disposed at an angleand the guide may include a generally wedge-shaped portion disposedbetween the fingers. The distal ends of the fingers may includeoutwardly extending portions and the outwardly extending portions may beused to form the undercuts. In a molding position, the distal ends ofthe fingers may be disposed a first distance away from the base of thetool and the outermost portions of the outwardly extending portions ofthe fingers may be spaced a first distance apart. When the blow-moldedplastic structure is formed, plastic may envelop or encircle the ends ofthe fingers and/or a portion of the guide, such as the wedge-shapedstructure. After the inwardly extending portion with the undercuts isformed, the blow-molded plastic structure may be moved away from theface of the mold and the fingers may move inwardly and at an anglerelative to the face of the mold. When the blow-molded plastic structurehas moved a distance away from the face of the mold, the distal ends ofthe fingers may be disposed a second distance away from the base of thetool and the outermost portions of the outwardly extending portions ofthe fingers may be spaced a second distance apart. When the distanceseparating the outermost portions of the outwardly extending portions ofthe fingers is less than the distance separating the innermost portionsof the undercuts, the blow-molded plastic structure may be removed orreleased from the mold.

Still another aspect is a method of manufacturing an undercut in ablow-molded plastic structure. The method may include placing a tool ina portion of a mold and the tool may be used to form the undercut. Themethod may also include forming a parison and closing the mold aroundthe parison. The parison may be inflated with a gas such as pressurizedair. The undercut may be formed by the tool and then the moldedstructure with the undercut may be released or removed from the mold.

Yet another aspect is a tool that may be used to create an undercut in ablow-molded plastic structure. The tool, for example, may create aninwardly extending portion with an undercut. The tool may include a baseand a surface of the base may help form a portion of the blow-moldedplastic structure. For instance, an upper surface of the base may begenerally aligned with a portion of the mold and the upper surface ofthe base may help form a portion of the blow-molded plastic structure.The base may include a first guide, such as a pathway or opening, and afirst finger may be at least partially disposed in the first guide. Thebase may also include a second guide, such as a pathway or opening, anda second finger may be at least partially disposed in the second guide.The first guide may help control movement of the first finger relativeto the base and the second guide may help control movement of the secondfinger relative to the base. The base may include an inwardly extendingprojection, which may also be referred to as a guide, and the inwardlyextending projection may have a generally wedge-shaped configuration.The guides may be sized and configured to allow the fingers to movebetween one or more positions relative to the base. For example, theguides may be sized and configured to allow the fingers to be disposedin a molding position and a release position. When the fingers are inthe molding position, the distal ends of the fingers may be disposed afirst distance away from the base and the distal ends of the fingers mayinclude outwardly extending portions. In the molding position, the outerportion of the outwardly extending portions may be separated by adistance and the outwardly extending portions may be used to form atleast a portion of the undercut. When the fingers are disposed in therelease position, the ends of the fingers may be spaced apart from thebase of the mold by a second distance and the outmost portions of theoutwardly extending portions of the fingers may be separated by a seconddistance. When the distance separating the outmost portions of theoutwardly extending portions of the fingers is less than a distanceseparating the innermost portion of the inwardly extending portion ofthe blow-molded plastic structure, the structure may be removed orreleased from the tool.

Still yet another aspect is a method of manufacturing a blow-moldedplastic structure that may comprise placing a tool in a portion of amold for blow-molding a plastic structure, forming a parison of moltenplastic, disposing the parison of molten plastic in the mold, closingthe mold around the parison of molten plastic, inflating the parison,and creating an inwardly extending portion with an undercut with thetool. The method may include releasing the inwardly extending portionwith the undercut from the tool by moving the tool from a moldingposition to a release position. The method may include concurrentlyreleasing the molded plastic structure from the mold and releasing theinwardly extending portion with the undercut from the tool. The methodmay include creating a receiving portion disposed between an uppersurface of the undercut and an upper surface of the inwardly extendingportion. The method may include creating an edge of the undercut and theedge may be disposed at an acute angle relative to a surface of theundercut, the acute angle may be about ninety degrees (90°), abouteighty five degrees (85°), about eighty degrees (80°), about seventyfive degrees (75°), about seventy degrees (70°), or less than aboutseventy degrees (70°).

A further aspect is a tool that may be used to create an undercut in ablow-molded plastic structure constructed using a blow-molded process,the tool may comprise a base; a first guide at least partially disposedin the base; a second guide at least partially disposed in the base; afirst finger at least partially disposed in the first guide, the firstfinger being movable relative to the base between a molding position anda release position, the first finger including an elongated body and anoutwardly extending portion; and a second finger at least partiallydisposed in the second guide, the second finger being movable relativeto the base between a molding position and a release position, thesecond finger including an elongated body and an outwardly extendingportion. When the first finger and the second finger are disposed in themolding position, an upper surface of the outwardly extending portion ofthe first finger and an upper surface of the outwardly extending portionof the second finger may be generally aligned in the same plane; andwhen the first finger and the second finger are disposed in the releaseposition, the upper surface of the outwardly extending portion of thefirst finger and the upper surface of the outwardly extending portion ofthe second finger may be generally aligned in the same plane. When thefirst finger and the second finger are disposed in the molding position,an upper surface of the outwardly extending portion of the first fingerand an upper surface of the outwardly extending portion of the secondfinger may be disposed a first distance from the base; and when thefirst finger and the second finger are disposed in the release position,the upper surface of the outwardly extending portion of the first fingerand the upper surface of the outwardly extending portion of the secondfinger may be disposed a second distance from the base, the seconddistance may be greater than the first distance. The first finger maymove along a first axis that is disposed at an angle relative to thebase and the second finger may move along a second axis that is disposedat an angle relative to the base, the angle of the first axis relativeto the base may be generally the same as the angle of the second axisrelative to the base. The outwardly extending portion of the firstfinger may be disposed a first distance from the outwardly extendingportion of the second finger when the first finger and the second fingerare in the molding position; the outwardly extending portion of thefirst finger may be disposed a second distance from the outwardlyextending portion of the second finger when the first finger and thesecond finger are in the release position; and the second distance maybe smaller than the first distance to allow the outwardly extendingportion of the first finger and the outwardly extending portion of thesecond finger to be removed from the undercut formed in the blow-moldedplastic structure.

Another aspect is a table that may include a blow-molded plastic tabletop. The blow-molded plastic table top may be constructed using ablow-molding process and the table top may include an upper surface, alower surface, a frame receiving portion disposed in the lower surfaceof the table top, a first frame connecting structure with an undercutdisposed in a first portion of the frame receiving portion, and a secondframe connecting structure with an undercut disposed in a second portionof the frame receiving portion. A frame may be connected to the tableand a first portion of the frame may contact the first frame connectingstructure and a second portion of the frame may contact the second frameconnecting structure. The table may include one or more support membersthat are sized and configured to support the table top above a surface.

Still another aspect is the first portion of the frame may engage alower surface of the undercut of the first frame connecting structureand the second portion of the frame may engage a lower surface of theundercut of the second frame connecting structure. The first frameconnecting structure may be disposed on a first side of the framereceiving portion and the second frame connecting structure may bedisposed on a second side of the frame receiving portion. The first fameconnecting structure may be an outwardly extending structure with anundercut. The second fame connecting structure may be an inwardlyextending structure with an undercut. The frame may be connected to thetable top without the use of any fasteners. The table top, including theupper surface, the lower surface, the frame receiving portion, the firstframe connecting structure with an undercut, and the second frameconnecting structure with an undercut, may be integrally formed as partof a unitary, one-piece structure during the blow-molding process. Aportion of the frame may be inserted into the frame receiving portionand then the frame may be moved within the frame receiving portion toengage the first portion of the frame with the undercut of the firstframe connecting structure and to engage the second portion of the framewith the undercut of the second frame connecting structure. The framemay include a cutout and the cutout may allow the frame to be insertedinto the frame receiving portion. The frame may include one or moreoutwardly extending tabs and the table top may include one or morereceiving portions, and the tabs may be disposed in the receivingportions when the frame is connected to the table top.

Yet another aspect is a method of connecting a frame to a blow-moldedplastic table top. The method may include providing a table top with aframe receiving portion, the frame receiving portion may include a firstframe connecting structure with an undercut disposed in a first portionof the frame receiving portion and a second frame connecting structurewith an undercut disposed in a second portion of the frame receivingportion. The method may also include inserting a portion of the frameinto the frame receiving portion and moving the frame relative to thetable top so that a first portion of the frame may contact the firstframe connecting structure and a second portion of the frame may contactthe second frame connecting structure. In addition, the first portion ofthe frame may engage a lower surface of the undercut of the first frameconnecting structure and the second portion of the frame may engage alower surface of the undercut of the second frame connecting structure.The first frame connecting structure may be disposed on a first side ofthe frame receiving portion and the second frame connecting structuremay be disposed on a second side of the frame receiving portion. Thefirst portion of the frame may engage the undercut of the first frameconnecting structure and the second portion of the frame may engage theundercut of the second frame connecting structure. The frame may includeone or more outwardly extending tabs and the table top may include oneor more receiving portions, and the tabs may be disposed in thereceiving portions when the frame is connected to the table top.

These and other aspects, features and advantages of the presentinvention will become more fully apparent from the following briefdescription of the drawings, the drawings, the detailed description ofpreferred embodiments and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The appended drawings contain figures of exemplary embodiments tofurther illustrate and clarify the above and other aspects, advantagesand features of the present invention. It will be appreciated that thesedrawings depict only exemplary embodiments of the invention and are notintended to limit its scope. Additionally, it will be appreciated thatwhile the drawings may illustrate preferred sizes, scales, relationshipsand configurations of the invention, the drawings are not intended tolimit the scope of the claimed invention. The invention will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1A is a upper perspective view of an exemplary molded plasticstructure and a support, such as a frame;

FIG. 1B is an upper perspective view of the molded plastic structure andframe shown in FIG. 1A, illustrating the frame and molded plasticstructure disposed in a first position;

FIG. 1C is an upper perspective view of the molded plastic structure andframe shown in FIG. 1A, illustrating the frame and molded plasticstructure disposed in a second position;

FIG. 2A is a upper perspective view of an exemplary molded plasticstructure and a support, such as a frame;

FIG. 2B is an upper perspective view of the molded plastic structure andframe shown in FIG. 2A, illustrating the frame and molded plasticstructure disposed in a first position;

FIG. 2C is an upper perspective view of the molded plastic structure andframe shown in FIG. 2A, illustrating the frame and molded plasticstructure disposed in a second position;

FIG. 3A is cross-sectional side view along lines 3A-3A shown in FIG. 1B;

FIG. 3B is cross-sectional side view along lines 3B-3B shown in FIG. 1C;

FIG. 3C is a cross-sectional side along lines 3C-3C;

FIG. 4A is cross-sectional side view along lines 4A-4A shown in FIG. 1B;

FIG. 4B is cross-sectional side view along lines 4B-4B shown in FIG. 1C;

FIG. 5A is an enlarged upper perspective view of an exemplary moldedplastic structure;

FIG. 5B is another enlarged upper perspective view of an exemplarymolded plastic structure;

FIG. 6A is an enlarged perspective view of an exemplary support, such asa frame; and

FIG. 6B is another enlarged perspective view of an exemplary support,such as a frame.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

The following exemplary embodiments are generally described inconnection with blow-molded plastic structures such as a table top. Theprinciples of the present invention, however, are not limited to a tabletop. In particular, the principles of the present invention may beimplemented in other articles of furniture and in other structures thatinclude blow-molded plastic components. In addition, it will beunderstood that, with the benefit of the present disclosure, thestructures can have a variety of shapes, sizes, configurations, andarrangements. Moreover, the invention disclosed herein and componentsthereof may be successfully used in connection with other types ofstructures such as furniture (e.g., tables, picnic tables, chairs,etc.), objects (e.g., sheds, deck boxes, coolers, garden boxes,playground equipment, sporting goods, water sports equipment, etc.), andthe like.

To assist in the description of exemplary embodiments shown in theaccompanying figures, words such as top, bottom, front, rear, right andleft may be used. The accompanying figures may be, but are notnecessarily, drawn to scale. It will further be appreciated thestructures can be disposed in a variety of desired positions ororientations, and used in numerous locations, environments andarrangements. A detailed description of some exemplary embodiments ofthe structures now follows.

An exemplary structure may be constructed from molded plastic. Theexemplary molded plastic structure may be constructed from blow-moldedplastic. In the accompanying figures, the exemplary molded plasticstructure may be referred to as a table top or a portion of a table top.The table top may include an upper portion, a lower portion, and anouter boundary. The upper portion and the lower portion of the table topmay be spaced apart by a distance. The table top may include a hollowinterior portion disposed between the upper portion and the lowerportion. The hollow interior portion may be filled with foam or othersuitable materials, if desired.

The table top may further include one or more sides, corners, and ends.The table top may be integrally formed as part of unitary, one-piecestructure during the blow-molding process. It will be appreciated thatthe table top may have a variety of suitable shapes, sizes,configurations, and/or arrangements depending, for example, upon theintended use of the table. It will also be appreciated that the tabletop may be constructed using various materials and may include one ormore features, aspects, and the like. While the molded plastic structuremay be described as being a table top or a portion of a table top, itwill be appreciated that the molded plastic structure may anothersuitable structure such as a chair seat, shed, deck box, and the like.

Although not shown in the accompanying figures, the table may includeone or more support structures or legs, which may be sized andconfigured to support the table top above a surface such as the floor orground. The support structures may include one or more supports and thesupport structures may be movable between a use position and a collapsedor storage position. It will be appreciated that the table may includeany suitable number of support structures and/or legs depending, forexample, upon the intended use of the table. It will also be appreciatedthat the support structures and/or legs may have different shapes,sizes, configurations, and/or arrangements depending, for example, uponthe type or intended use of the table.

The table may include a frame that is connected to the table top. Theframe may support the table top and may facilitate attachment of thesupport structures to the table. The exemplary frame shown in theaccompanying figures may be a side rail of a frame and a table top mayinclude a side rail disposed proximate each side of the table top. Itwill be appreciated that the frame may have different shapes, sizes,configurations, and/or arrangements depending, for example upon the typeor intended use of the table. It will be appreciated that the frame andtable top may have other components, features, aspects, characteristicsand the like, if desired.

It will be appreciated with the benefit of the present disclosure thatthe table top and frame may include any suitable number of componentsand the components may have various sizes, shapes, configurations, andarrangements depending, for example, upon the intended use of the table.It will further be appreciated that the table top and frame may includeother components, features, aspects, characteristics and the like, ifdesired; but none of the features, aspects or components may berequired.

The table top may include one or more undercuts. For example, the tabletop may include an outwardly extending portion with an undercut. Asshown in the accompanying figures, the outwardly extending portion mayextend outwardly from a portion of the table top and it may include aprojection with an undercut. For instance, the outwardly extendingportion may include a ramp or sloped surface and an overhang. A reliefor recess may be disposed under the overhang and the lower surface ofthe overhang may include a generally planar surface. The lower surfaceof the overhang may be disposed at an angle and the lower surface of theoverhang may be sized and configured to engage or contact a portion ofthe frame.

The table top may include an inwardly extending portion with anundercut. As shown in the accompanying figures, the inwardly extendingportion may extend inwardly into a portion of the table top and it mayinclude a projection with an undercut. The inwardly extending portionmay include an opening and a receiving portion. The inwardly extendingportion may include an undercut with a relief or recess and the lowersurface of the overhang may include a generally planar surface. Thelower surface of the undercut may be disposed at an angle and the lowersurface of the undercut may be sized and configured to engage or contacta portion of the frame.

The table top may include a frame receiving portion that is sized andconfigured to receive at least a portion of a frame. For example, theframe receiving portion may include a channel or recess disposed in alower portion of the table top. The frame receiving portion may includea first portion and a structure with an undercut may be disposed in thefirst portion of the frame receiving portion. The frame receivingportion may include a second portion and a structure with an undercutmay be disposed in the second portion of the frame receiving portion. Inan exemplary embodiment, the frame receiving portion may include a firstside with an undercut, such as an outwardly extending structure with anundercut, and a second side with an undercut, such as an inwardlyextending portion with an undercut. As shown in the accompanyingfigures, the undercut on the first side of the frame receiving portionmay be at least partially aligned with the undercut on the second sideof the frame receiving portion. After reviewing this disclosure, it willbe appreciated that any suitable number, shape, size, configuration,and/or arrangement of undercuts may be disposed on the first and/orsecond portions of the frame receiving portion. After reviewing thisdisclosure, it will also be appreciated that one or more undercuts maybe aligned, generally disposed in the same plane, disposed in asymmetrical configuration, and the like. The undercuts, however, do nothave to be aligned, generally disposed in the same plane, or disposed ina symmetrical configuration. Instead, the undercuts may be offset,spaced apart, and/or disposed in other suitable configurations andarrangements. Further, the undercuts may be any suitable combination ofoutwardly extending and/or inwardly extending structures depending, forexample, upon the intended use of the table.

The frame may be sized and configured to be at least partially disposedin the frame receiving portion. The frame may include one or moreopenings or cutouts to allow the frame to be at least partially disposedin the frame receiving portion. For example, the frame may includecutout that allows the frame to be disposed about the outwardlyextending structure with an undercut. The frame may also include asurface that is sized and configured to engage or contact acorresponding surface of the undercut when the frame is connected to thetable top.

The frame may include one or more tabs or outwardly extending portionsthat are sized and configured to be at least partially disposed in theinwardly extending structures with an undercut. For example, the tab maybe disposed in the opening of the inwardly extending structure when theframe is inserted into the frame receiving portion. The tab may includea surface that is sized and configured to engage or contact acorresponding surface of the undercut when the frame is connected to thetable top.

Advantageously, the frame and frame receiving portion may be sized andconfigured to allow the frame to be inserted into the frame receivingportion and then moved so that the frame engages the undercut on thefirst side of the frame receiving portion and the undercut on the secondside of the frame receiving portion. This may facilitate secureattachment of the frame to the table top because opposing portions ofthe frame may be secured to the table top.

For example, FIG. 1A illustrates an exemplary frame and exemplaryportion of a table top disposed in a generally vertically alignedconfiguration. As shown in FIG. 1B, the frame may be at least partiallydisposed in a frame receiving portion of the table top. As shown in FIG.1C, the frame may be moved relative to the table top to connect theframe and table top.

FIGS. 2A-2C illustrate the connection of the frame and table top from adifferent viewpoint. For example, FIG. 2A illustrates the frame andportion of a table top in a generally vertically aligned configuration.FIG. 2B illustrate the frame at least partially disposed in the framereceiving portion of the table top. FIG. 2C illustrate the frame may bemoved relative to the table top to connect the frame and table top.

The frame and/or table top may include other features and aspects. Forexample, the table top may include one or more angled surfaces, such asramps, which may help position the frame relative to the table top. Theangled surfaces may also help prevent unintentional detachment of theframe from the table top. The table top may also include one or morereceiving portions that are sized and configured to receiving a portionof the frame. The receiving portions may receive a portion of the frameand may help prevent inadvertent disconnection of the frame and tabletop. For instance, the frame may include an outwardly extending portionand the outwardly extending portion may move along an angled surfacewhen the frame is being moved within the frame receiving portion to alocked position. When the frame is disposed in the locked position, theoutwardly extending portion may be disposed in the receiving portion andengagement of the outwardly extending portion with the receiving portionmay help secure the frame in a locked position.

The inwardly or outwardly extending portions with an undercut cannot beformed with traditional blow-molding techniques. Instead, a tool allowsthe inwardly extending portion with an undercut to be formed during theblow-molding process. The exemplary tool may include a base, a firstfinger, and a second finger. The first and second fingers may be movablebetween a molding position in which the blow-molded structure may beformed and a release position in which the blow-molded structure may bereleased from the tool. The first finger may include a stop and thesecond finger may include a stop, and the stops may help controlmovement of the fingers. For example, the stops may help position thefingers in the molding position and/or the release position. The fingersmay also include more than one stop, which may help position the fingersin the molding position and/or the release position. The first andsecond fingers may include an end, such as a distal end, that extendsoutwardly relative to an upper surface of the base. A portion of thefirst and second fingers, which may include the distal ends, may besized and configured to contact or touch the plastic during theblow-molding process. Thus, the distal ends of the fingers may help formthe plastic into the desired shape during the molding process. The firstand second fingers may also include another end, such as a proximal end,and the proximal end of the fingers may be disposed at least proximate alower surface of the base. The fingers may be connected to a device,such as a motor, cam, piston, driver, and the like, and the device mayhelp control movement of one or more of the fingers. For example, thedevice may move the fingers between the molding position and the releaseposition.

The fingers may include outwardly extending portions and the outwardlyextending portions may be sized and configured to form the undercuts inthe inwardly extending portions. In greater detail, an outwardlyextending portion may be disposed at the distal end of each finger andthe outwardly extending portions may extend in opposing directions. Forexample, in the molding position, the outwardly extending portions mayextend in opposite directions and the outwardly extending portions maybe disposed in generally the same plane. The outwardly extendingportions may include a generally planar first surface and a generallyplanar second surface that are separated by a distance. The first andsecond generally planar surfaces may be generally aligned in parallelplanes. The first and second generally planar surfaces, however, do nothave to be aligned or disposed in generally parallel planes. Forexample, the first and second generally planar surfaces could bedisposed at an angle depending, for example, upon the type of undercutto be formed. The outwardly extending portions may also include an outeredge or wall that extends between the first and second surfaces.

When the tool is disposed in the molding position, an upper surface ofthe first and second fingers and/or an upper surface of the outwardlyextending portions may be generally aligned and/or disposed in the sameplane. The upper surfaces of the first and second fingers and/or theupper surfaces of the outwardly extending portions may also be alignedwith a portion of the base, such as an upper surface of the guide. Theguide may have a generally wedge or triangular-shaped configuration andthe upper surface of the first and second fingers and/or an uppersurface of the outwardly extending portions may be generally alignedwith the upper surface of the guide. In the molding position, the outersurfaces of the fingers proximate the base may be separated by a firstdistance, the outer surfaces of the fingers proximate the outwardlyextending portions may be separated by a second distance, and theoutermost ends or edges of the outwardly extending portions of thefingers may be separated by a third distance. The first distance may begreater than the second distance or the third distance, and this portionof the tool may form the base of the inwardly extending portion duringthe molding process. The second distance may be smaller than the firstdistance and the third distance, and the second distance may helpidentify the narrowest portion of the inwardly extending portion. Thethird distance may be smaller than the first distance and larger thanthe second distance, and the third distance may help identify theundercut.

When the blow-molded structure is being formed, the plastic may contactand be disposed about an upper, exterior portion of the first and secondfingers, the outwardly extending portions, and a portion of the base,such as a portion of the guide and/or the upper surface of the base.Advantageously, the tool may allow the inwardly extending portion withthe undercut to be created during the blow-molding process. In addition,the structure may be removed from the tool after the structure is formedwithout any, or substantially without any, deformation of the moldedplastic structure. Significantly, the undercut can include planarsurfaces and/or sharp angles, which may facilitate secure connection forcomponents, such as fasteners, connectors, or other objects, to thechair seat.

Structures constructed from blow-molded plastic may have unique anddistinctive properties, and some aspects of blow-molding may not becompatible with other types of molding such as injection molding,rotational molding, vacuum fuming, and the like. For example, because ablow-molded plastic structure is formed by using air or gas to inflate aparison of molten plastic, some features or structures that can be madefrom some types of molding processes cannot be manufactured using knownblow-molding techniques. In addition, a blow-molded plastic structure isgenerally formed with an outer surface of the structure engaging theface of the mold and a hollow interior that is filled with pressurizedgas during the molding process. Thus, blow-molded plastic structures maynot be manufactured with the devices, molds, structures, and the like ofother types of molding processes because of the different properties andconfigurations of blow-molded plastic structures. Further, because mostblow-molded plastic structures include opposing walls separated by adistance and enclosing a hollow interior portion, processes orstructures that may work with a single layer of material may not workwith a blow-molded structure. Accordingly, after reviewing thisdisclosure, one skill in the art will appreciate the significantdifferences between the blow-molded plastic structures and methodsdisclosed herein, and other types of molded plastic structures andmethods.

One of ordinary skill in the art may appreciate after reviewing thisdisclosure that the chair seat and structures disclosed herein may havea number of different aspects, features, characteristics andconfigurations. Further, chair seat and structures may have any suitablenumber of aspects, features, characteristics and configurationsdepending, for example, upon the intended use of the chair or otherstructure.

One of ordinary skill will appreciate that the structures disclosedherein may have various suitable sizes, shapes, configurations, and/orarrangements. Other exemplary configurations are shown below:

Although this invention has been described in terms of certain preferredembodiments, other embodiments apparent to those of ordinary skill inthe art are also within the scope of this invention. Accordingly, thescope of the invention is intended to be defined only by the claimswhich follow.

What is claimed is:
 1. A table comprising: a blow-molded plastic tabletop constructed using a blow-molding process, the table top comprising:an upper surface; a lower surface; a frame receiving portion disposed inthe lower surface of the table top; a first frame connecting structurewith an undercut disposed in a first portion of the frame receivingportion; and a second frame connecting structure with an undercutdisposed in a second portion of the frame receiving portion; a frameconnected to the table top, a first portion of the frame contacting thefirst frame connecting structure, a second portion of the framecontacting the second frame connecting structure; and one or moresupport members that are sized and configured to support the table topabove a surface.
 2. The table of claim 1, wherein the first portion ofthe frame engages a lower surface of the undercut of the first frameconnecting structure; and wherein the second portion of the frameengages a lower surface of the undercut of the second frame connectingstructure.
 3. The table of claim 1, wherein the first frame connectingstructure is disposed on a first side of the frame receiving portion andthe second frame connecting structure is disposed on a second side ofthe frame receiving portion.
 4. The table of claim 1, wherein the firstfame connecting structure comprises an outwardly extending structurewith an undercut.
 5. The table of claim 1, wherein the second fameconnecting structure comprises an inwardly extending structure with anundercut.
 6. The table of claim 1, wherein the frame is connected to thetable top without the use of any fasteners.
 7. The table of claim 1,wherein the upper surface, the lower surface, the frame receivingportion, the first frame connecting structure with an undercut, and thesecond frame connecting structure with an undercut are integrally formedas part of a unitary, one-piece structure during the blow-moldingprocess.
 8. The table to claim 1, wherein a portion of the frame isinserted into the frame receiving portion and then the frame is movedwithin the frame receiving portion to engage the first portion of theframe with the undercut of the first frame connecting structure and toengage the second portion of the frame with the undercut of the secondframe connecting structure.
 9. The table of claim 1, further comprisinga cutout in the frame, the cutout allowing the frame to be inserted intothe frame receiving portion.
 10. The table of claim 1, furthercomprising one or more outwardly extending tabs of the frame and one ormore receiving portions in the table top, the tabs being disposed in thereceiving portions when the frame is connected to the table top.
 11. Amethod of connecting a frame to a blow-molded plastic table top, themethod comprising: providing a table top with a frame receiving portion,the frame receiving portion including a first frame connecting structurewith an undercut disposed in a first portion of the frame receivingportion and a second frame connecting structure with an undercutdisposed in a second portion of the frame receiving portion; inserting aportion of the frame into the frame receiving portion; and moving theframe relative to the table top so that a first portion of the framecontacts the first frame connecting structure and a second portion ofthe frame contacts the second frame connecting structure.
 12. The methodof claim 11, wherein the first portion of the frame engages a lowersurface of the undercut of the first frame connecting structure; andwherein the second portion of the frame engages a lower surface of theundercut of the second frame connecting structure.
 13. The method ofclaim 11, wherein the first frame connecting structure is disposed on afirst side of the frame receiving portion and the second frameconnecting structure is disposed on a second side of the frame receivingportion.
 14. The method of claim 11, wherein the first portion of theframe engages the undercut of the first frame connecting structure; andwherein the second portion of the frame engages the undercut of thesecond frame connecting structure.
 15. The method of claim 11, furthercomprising one or more outwardly extending tabs of the frame and one ormore receiving portions in the table top, the tabs being disposed in thereceiving portions when the frame is connected to the table top.